Komatsu 830E Dump Truck Shop Manual CEBM013200 – PDF DOWNLOAD

Description

Komatsu 830E Dump Truck Shop Manual CEBM013200 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 830E Dump Truck Shop Manual CEBM013200 – PDF DOWNLOAD

Language : English
Pages :783
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 830E Dump Truck Shop Manual CEBM013200 – PDF DOWNLOAD’

FOREWORD

This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck.

• safety notices, warnings and cautions should be understood and followed when accomplishing repairs on the truck. The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually.
• For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck.
• Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model. This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to “Right”, “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise.
• Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have ±10% tolerance unless otherwise specified. A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
• The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 830E). The three numbers represent the basic truck model. The letter “E” designates an Electrical propulsion system. The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.

TABLE OF CONTENTS:

Komatsu 830E Dump Truck Shop Manual CEBM013200 – PDF DOWNLOAD

MAIN MENU 0
COVER 1
FOREWORD 5
CONTENTS 7
GENERAL INFORMATION 9
Truck Component Description and Specifications 11
General Safety and Truck Operation 15
Precautions During Operation 19
Battery 24
Precautions For Maintenance 25
During Maintenance 26
Tires 29
Additional Job Site Rules 30
When Repairs Are Necessary 31
Operating Instructions 33
Warnings and Cautions 47
Charts and Tables 55
Storage Procedures 61
Short Term Idle Periods 61
Preparation for Storage 62
Removal from Storage 63
Reconditioning an Idle Vehicle 65
Engine Operation 68
After Engine Has Started 69
Engine Storage-Cummins 70
Engine Storage (Short Term) 70
Engine Storage (Long Term) 71
Engine Storage- Detroit Diesel 72
Preparing for Storage 72
Temporary Storage (30 Days or Less) 72
Extended Storage (More than 30 Days) 72
Procedure for Restoring an Engine to Service Which Has Been in Extended Storage 74
Electric Drive Trucks 75
Preservation and Storage- Allison Transmission 79
STRUCTURES 81
Structural Components 83
Ladders 83
Right Hand Deck 84
Removal 84
Installation 84
Center and Left Hand Deck Components 85
Fuel Tank 86
Removal 86
Installation 86
Dump Body 87
Removal 87
Installation 88
Body Pads 89
Adjustment 90
Body Guide 90
Body-Up Retention Cable 90
Body Position Indicator 91
Rock Ejectors 91
Inspection 91
Hoist Limit Switch 91
Body Up Switch 91
ENGINE 93
Power Module 95
Preparation 95
Removal 95
Installation 99
Cooling System101
Cooling System Description101
Radiator102
Removal102
Installation104
Radiator Filling Procedure104
Power Train105
Alternator Removal Procedure105
Engine Alternator Mating107
Measuring Procedure107
Joining Alternator and Engine109
Engine110
Removal110
Installation110
Air Filtration System111
Air Cleaner111
Operation111
General Service Information111
Main Filter Element111
Safety Filter Element112
Air Intake Troubleshooting113
Air Cleaner Assembly Cleaning113
Main Filter Cleaning113
Precleaner Section Cleaning114
ELECTRICAL SYSTEM (24VDC NON-PROPULSION)117
24VDC Electric Supply System119
Electrical System Description119
Battery- Maintenance and Service119
Troubleshooting119
Battery Charging System (Niehoff)121
General Description121
Troubleshooting Procedures121
On Vehicle Troubleshooting Guide- Self Energized Alternator124
Advanced System Troubleshooting126
24VDC Electric Starter System (with Prelube)128
Operation128
Maintenance129
Troubleshooting130
24VDC Electric Start System132
Troubleshooting133
24VDC Electrical System Components141
Passenger Seat Base Compartment141
Components141
Alarm Indicating Device144
Battery Equalizer146
Body-Up Switch147
Hoist Limit Switch147
24Volt Relay and Diode Boards148
Circuit Breaker Chart154
ELECTRICAL PROPULSION COMPONENTS155
Electrical Propulsion Components157
General System Description157
Control System157
FL275 Panel159
Card Replacement160
Card Repair160
Computer Description161
Software161
2-Digit Display Panel164
Events164
Frames165
Windows165
2 Digit Display Panel Codes (Table I)167
Subcode Descriptions (Table II)174
Portable Test Unit (PTU)177
Description177
Software Installation Preparation178
The Main Menu180
PTU Software Menu Tree181
Configuration (CFG) File Conversion182
Statex Configuration Files186
Programming The Truck197
PTU Hookup197
Download Configuration Files199
Event Data201
Statistical Data203
Statistical Data Codes- Counters (Table III)204
Statistical Data Codes- Profiles (Table IV)210
Truck Specific Information214
Temporary Truck Settings215
Miscellaneous Software Features216
Saving Data216
PTU Abbreviations217
Other Menu Selections217
Miscellaneous Electrical Propulsion Components218
Alternator218
Electric Wheel Motors218
Electronic Accelerator and Retard Control218
Cooling Blower Warning System220
Electrical Control Cabinet221
Statex III Electric Drive Components Abbreviations226
Statex III Electrical System Checkout Procedure229
General Information231
Communications Port Check232
PTU Hookup232
10 Sequence Tests234
Throttle System Check and Adjustment235
Electronic Throttle System235
Electronic Throttle System fuel Enhancement (“Fuel Saver”)236
Retard System Check and Adjustment- Electronic Pedal System238
Williams Electronic Retard Pedal and ACC/RET or RET Interface238
Electronic Retard Pedal, Current Production Trucks239
Reverser and Propulsion Contractors Check241
Propulsion Lockout Test (DDEC&MTU Engine Trucks Only)242
Retard Contractors Operation Check243
Ground Fault Sensing Check243
Ground Fault in Retard Operation Check243
Override Operation Check244
Anti-Reversal Function (AR) Check245
Overspeed Retard Operation Check245
Hoist Interlock Operation Check246
Motor Blower Fault Light Operation Check247
Digital Input/Output Signals Tests- FL275 Card Panel248
Setup Manual Digital Input/Output Test on PTU248
Digital Input Checks249
Digital Output Checks251
Analog Input Signals Test- FL275 Card Panel254
Setup Analog Input Monitor Screen on PTU254
Analog Input Checks255
Frequency Input Checks262
Speed Event Checks264
Single Speed Overspeed-Overspeed Settings Check265
Empty Truck- 2 Speed Overspeed Settings Check265
Loaded Truck- 2 Speed Overspeed Settings Check265
Other Speed Events Checks265
Retard Speed Control System Check267
Overspeed Pickup and Dropout Check267
Retard Pot Maximum Setting Check268
Retard Pot Minimum Setting Check268
Accelerator Pedal Override of Retard Speed Control268
Load Test Using Truck Retard Grids269
Load Test270
Motor Field current Check in Retarding271
Retard Check271
Miscellaneous Component Test and Adjustment272
Brake System Interlocks Check272
Blower Loss Pressure Switch Adjustment273
SYNC Transformer Checkout273
Power Contactor Position Sensor Adjustment273
Battery Boost Adjustment274
Isolation Amplifier& Voltage Module Test274
Voltage Measuring Module Test (VMM1&VMM2)274
ISO-AMP Test275
Motor Rotation Test275
Ground Fault Checks276
Optional Payload Meter (PLM II) Check-Out Procedure277
Check the Deck Mounted Lights277
Check Pressure Sensors277
Check Operation of Data Storage Trigger Module277
Zero the Angle Sensor277
Check Body-Up Switch Function277
Miscellaneous Charts278
Wheel Motor Gear Ratios278
Maximum Allowable Truck Speeds279
Engine Options280
DRIVE AXLE, SPINDLE AND WHEELS281
Tires and Rims283
Front Tires and Rims283
Removal283
Installation284
Rear Tires and Rims285
Removal285
Installation286
Rim287
Tire Removal287
Rim and Tire Preparation287
Lubricants288
Tire Installation288
Front Wheel Hub and Spindle291
Wheel Hub and Spindle Assembly291
Removal291
Spindle Pusher Tool Usage292
Installation293
Disassembly295
Cleaning and Inspection295
Assembly296
Wheel Bearing Adjustment298
Wheel Bearing Adjustment (Tire Mounted)298
Steering Cylinders and Tie Rod300
Spherical Bearing Wear Limits300
Removal301
Installation301
Bearing Replacement301
Toe-In Adjustment303
Rear Axle Housing Attachment305
Pivot Pin305
Removal305
Installation305
Pivot Eye Bearing306
Disassembly306
Assembly306
Pivot Eye Repair307
Removal307
Disassembly307
Assembly307
Installation307
Anti-Sway Bar308
Removal308
Installation308
Disassembly308
Cleaning and Inspection308
Assembly308
Rear Axle Housing309
Rear Axle Housing309
Removal309
Installation309
Wheel Motor309
Removal309
Cleaning and Inspection310
Installation310
HYDRAIR II SUSPENSIONS311
Front Suspension313
Removal313
Installation314
“Turn of the Nut” Tightening Procedure316
Minor Repair317
Bearing Structure Removal317
Bearing Structure Installation317
Major Suspension Rebuild318
Disassembly318
Assembly319
Pressure Test320
Rear Suspension321
Removal321
Installation323
Disassembly325
Cleaning and Inspection325
Assembly325
Pressure Test326
Oiling and Charging Procedure327
General327
Equipment List327
Front Suspension329
Front Suspension Oiling329
Front Suspension Nitrogen Charging330
Rear Suspension331
Rear Suspension Oiling331
Rear Suspension Nitrogen Charging332
Oil and Nitrogen Specifications Chart334
BRAKE CIRCUIT335
Brake Circuit337
Service Brake Circuit Operation337
Secondary Braking and Automatic Apply339
Parking Brake Circuit339
Brake Lock Circuit340
Warning Circuit340
Brake Circuit Component Service343
Brake Valve343
Removal343
Installation345
Disassembly346
Cleaning and Inspection348
Assembly348
Differential Pressure Switch351
Disassembly351
Cleaning and Inspection351
Assembly351
Valve Bench Test and Adjustment352
Test Set Up Procedure353
Differential Pressure Switch Test353
Final Test and Adjustment354
Installation of Brake Pedal Actuator Assembly to Brake Valve355
Brake Valves with Integral Mounted Electronic Retard Pedal356
Hydraulic Brake Accumulators357
Removal357
Installation357
Disassembly357
Cleaning and Inspection358
Assembly359
Brake Circuit Check-Out Procedure361
Equipment Required363
Initial System Set-Up364
Parking Brake364
Brake System Check-Out364
Failure Modes Check-Out365
Brake Circuit and Brake Valve Troubleshooting367
Hydraulic Brake System Check-Out Procedure Data Sheet371
Rockwell Wheel Speed Front Disc Brakes373
Brake Caliper373
Brake Lining377
Front Service Brake Conditioning (Burnishing) Procedure378
Brake Bleeding Procedures379
Rockwell Armature Speed Rear Disc Brakes381
Rear Brakes381
Caliper, Disc and Parking Brake381
Caliper Piston386
Bench Test392
Brake Lining393
Service Brake Conditioning (Burnishing) Procedure396
Brake Bleeding Procedure398
Rockwell Disc Parking Brake399
Park Brake Caliper399
Removal399
Installation400
Parking Brake Adjustment400
Park Brake Caliper Disassembly402
Cleaning and Inspection402
Park Brake Caliper Assembly403
Park Brake Lining Replacement404
Park Brake Burnish Procedure404
Brake Bleeding Procedure404
HYDRAULIC SYSTEM405
Hydraulic System407
Component Description408
Hydraulic System Component Repair411
Hoist Pump411
Hydraulic Tank422
Hydraulic Tank Strainers423
Hydraulic Tank Breathers424
Hoist Circuit Filters424
Filter Element Replacement425
Steering Circuit427
Steering Circuit Operation427
Component Description428
Steering Control Unit428
Flow Amplifier428
Bleed Down Manifold438
Accumulators439
High Pressure Filter439
Steering/ Brake Pump439
Operation440
Steering Circuit Component Repair445
Bleed Down Manifold445
Accumulator446
Steering Accumulator Charging Procedure450
Flow Amplifier451
Steering Control Unit456
Steering Cylinder462
Steering Circuit Filter463
Steering and Brake Pump465
Hoist Circuit477
Hoist Circuit Operation477
Component Description478
Hydraulic Tank478
Hoist Pump478
High Pressure Filters478
Hoist Valve479
Hoist Pilot Valve480
Hoist Up Limit Solenoid480
Pilot Operated Check Valve480
Counterbalance Valve Manifold480
Hoist System Operation Modes481
Hoist Circuit Component Repair493
Hoist Valve493
Inlet Section494
Spool Section496
Hoist Pilot Valve499
Body Up Limit Solenoid502
Pilot Operated Check Valve502
Hoist Cylinders502
Counterbalance Manifold510
Disabled Truck Dumping Procedure511
Hydraulic Checkout Procedure513
Steering and Brake Pump513
Bleed Down Manifold514
Shock and Suction Valves515
Leakage Tests516
Troubleshooting Chart518
Steering Circuit518
Steering Pump520
Flow Amplifier522
Checking Hoist System Pressures524
Hoist Counterbalance Valve Adjustment526
Troubleshooting Guide (Hoist Pump)528
Hydraulic System Flushing Procedure530
OPTIONS AND SPECIAL TOOLS531
Ansulfire Control System Manual533
Operation533
Inspection and Maintenance533
Recharging Procedures534
Alternator and Wheelmotor Cooling Air Filter System535
System Adjustment535
Pump535
Blower Drive Motor538
Blower Bearing Repair541
Air Cleaner542
Wiggins Quick Fill Fuel System543
Fuel Receiver543
Tank Breather Valve544
Buckeye Quick Fill Fuel System547
Tank Breather Valve547
Fuel Receiver548
Engine Coolant Heater549
Heating Element549
Thermostat550
Special Tools551
Air Conditioning System557
Environmental Impact557
Operator Cab Air Conditioning558
Principles of Refrigeration558
Air Conditioner System Components560
Electrical Circuit562
System Servicing564
Service Tools and Equipment567
Manifold Gauge Set569
System Performance Test572
System Leak Testing573
System Repair574
Evacuating the System581
Troubleshooting583
Preventive Maintenance Schedule for A/C Systems591
Radiator Shutters593
Payload Meter III597
Operation Section600
Introduction600
Data Summary600
Data Gathering600
Component Description601
System Diagram601
Suspension Pressure Sensors601
Inclinometer601
Operator Display601
Operator Switch602
Speed Input602
Body Up Switch602
Brake Lock Switch602
Payload Meter602
Communications Ports602
Kewswitch Input603
Payload Meter Power603
Load Lights603
Wiring and Termination604
TCI Outputs604
Operator’s Display and Switch605
Reading the Speedometer605
Reading the Load Display605
Using the Operator ID605
Using the Load and Ton Counter605
Total Ton Counter605
Total Load Counter606
Clearing the Counters606
Viewing Live Sensor Data606
Other Display Messages606
Payload Operation & Calculation607
Description of Haul Cycle States607
States or Stages of a Typical Haul Cycle607
Haul Cycle Description607
Load Calculation608
Carry Back608
Measurement Accuracy608
Sources for Payload Error608
Payload Error608
Loading Conditions609
Pressure Sensors609
Swing Loads609
Speed and Distance609
Haul Cycle Data609
Haul Cycle Data610
Haul Cycle Warning Flags611
Alarm Records612
Frame Torque Data612
Sprung Weight Data613
Maximum Speed Data613
PC Software Overview613
PC Overview613
System Configuration613
Installing the PLM III Software613
Downloading Data614
PLM III System Configuration615
Starting Communications615
Displayed Payload Units615
Time Units615
Connection Menu615
Connecting to the Payload Meter616
Configure the Payload Meter616
Setting the Date and Time616
Setting the Truck Type617
Setting the Gauge Display Units617
Setting the Frame Serial Number617
Setting the Truck Number617
Setting the Komatsu Customer617
Clean Truck Tare618
Inclinometer Calibration618
Data Analysis619
Creating a Query619
Sorting on Truck Type619
Sorting on Date Range620
Sorting on Time Range620
Payload Detail Screen621
Creating Reports621
Summary – One Page Report622
Detailed – Multi Page Report622
Creating Graphs623
Exporting Data623
CSV Export623
Compressed624
Importing Data625
Deleting Haul Cycle Records625
Viewing Alarms626
Deleting Alarm Records626
Troubleshooting Section627
Troubleshooting627
Viewing Active Alarms627
Real-Time Data Display627
Testing the Payload Lights627
Creating Log Files of Inputs628
Daily Inspections628
Periodic Maintenance628
Abnormal Displays at Power-Up629
No Payload Display When Key Switch is Turned ON630
No Display on Speedometer631
No Display on Operator Display631
No Communication With PC632
Load Lights Don’t Light During Loading633
Load Lights Remain ON634
Load Lights Remain ON During Dumping634
Display Doesn’t Clear When the Load is Dumped634
Calibration Problems635
Alarm 1-Left Front Pressure High636
Alarm 2-Left Front Pressure Low636
Troubleshoot Wiring to Left Front Suspension636
Alarm 3-Right Front Pressure High637
Alarm 4-Right Front Pressure Low637
Troubleshooting Wiring to Right Front Suspension637
Alarm 5-Left Rear Pressure High638
Alarm 6-Left Rear Pressure Low638
Troubleshooting Wiring to Left Rear Suspension638
Alarm 7-Right Rear Pressure High639
Alarm 8-Right Rear Pressure Low639
Troubleshoot Wiring to Right Rear Suspension639
Alarm 9-Inclinometer High640
Alarm 10-Inclinometer Low640
Troubleshoot Inclinometer Wiring640
Alarm 13-Body Up Input Failure641
Alarm 15-Memory Write Failure642
Alarm 16 – Memory Read Failure642
Alarm 24 – System Key-On Status642
Operator Switch Doesn’t Work643
Alarm 26 – User Switch Fault – Select643
Alarm 27 – User Switch Fault – Set643
Connector Map644
Connectors645
PLM III Check Out Procedure647
General Description647
Tools Required647
Check Out Procedure647
PLM III Check Out Procedure Confirmation651
Flashburn Programming651
Confirmation Checklist653
PLM III Components654
Pressure Sensor654
Controller654
Speedometer654
Reserve Engine Oil System655
OPERATOR’S CAB661
Truck Cab663
Description663
Removal664
Installation665
Cab Door666
Removal666
Installation666
Door Adjustment666
Door Jam Bolt Adjustment666
Door Handle Plunger Adjustment668
Replace Door Glass669
Replace Door Window Regulator673
Replace Door Handle or Latch Assembly673
Door and Door Hinge Seal Replacement674
Glass Replacement675
Adhesive Bonded Windows675
Windshield and Rear Glass676
Cab Components679
Windshield Wiper679
Windshield Washer681
Operator Comfort683
Operator Seat683
Adjustment683
Heater/ Air Conditioner Controls684
Heater Components685
Filter686
Operator Controls and Equipment689
Steering Wheel and Controls690
Steering Column690
Pedal Controls692
Overhead Controls, Gauges, Etc693
Center Console694
Hoist Control Lever695
Instrument Panel and Indicator Lights698
Control Symbols698
Instrument Panel699
Panel Gauges, Indicators and Controls700
Overhead Status / Warning Indicator Lights704
LUBRICATION AND SERVICE711
Lubrication and Service713
Lubrication Specifications Charts713
Service Capacities713
Hydraulic Tank Service and Filling Instructions713
Radiator Filling Procedure714
Anti-Freeze Specifications714
Reserve Engine Oil System714
Lubrication Chart- Oil and Grease Specifications715
10 Hour (Daily) Lubrication and Maintenance Checks716
50 Hour Lubrication and Maintenance Checks718
100 Hour Lubrication and Maintenance Checks719
250 Lubrication and Maintenance Checks720
500 Hour Lubrication and Maintenance Checks722
1000 Hour Lubrication and Maintenance Checks723
2500 Hour Lubrication and Maintenance Checks724
5000 Hour Lubrication and Maintenance Checks725
10,000 Hour Lubrication and Maintenance Checks725
Automatic Lubrication System727
General Description727
System Components729
System Operation730
Injector Operation732
General Instructions733
System Checkout736
Pump Rebuild737
System Troubleshooting Chart740
Preventative Maintenance Procedures743
Motorized Wheel Maintenance Schedule745
ALPHABETICAL INDEX749
SYSTEM SCHEMATICS753
HH353 HYDRAULIC SCHEMATIC755
HH354 BRAKE SCHEMATIC756
HE481 PLM III ELECTRICAL SCHEMATIC757
ES0600758
XS1401 INDEX AND SYMBOLS758
XS1402 CIRCUIT NUMBER LOCATION759
XS1403 COMPONENT LOCATOR760
XS1404 COMPONENT LOCATOR761
XS1405 POWER DISTRIBUTION – 24V762
XS1406 POWER 18 ELEMENT 3 STEP RETARDING763
XS1407 POWER 18 ELEMENT 7 STEP RETARDING764
XS1408 POWER 20 ELEMENT 7 STEP RETARDING765
XS1409 DRIVE SYSTEM CONTROL CIRCUITS766
XS1410 TWO DIGIT DISPLAY767
XS1411 GE DIGITAL INPUTS, AUTO LUBE CONTROL768
XS1412 REAR TAIL LIGHTS, DIMMER CONTROL769
XS1413 5 MINUTE IDLE, SPARE WIRES770
XS1414 WINDOWS, RADIO, GAUGES771
XS1415 CONTACTOR FEEDBACK772
XS1416 CONTACTOR COILS773
XS1417 MACHINE CONTROL CIRCUITS774
XS1418 ACCELERATOR, RETARD PEDALS775
XS1419 HYDRAULIC CONTROLS, ALARMS776
XS1420 HEATER/AC, WINDSHIELD WIPER CONTROLS777
XS1421 LIGHT CONTROL CIRCUITS778
XS1422 INSTRUMENT LIGHTS, DIAGNOSTIC PORTS779
XS1423 MOD MINING DISPATCH780
XS1424 CUMMINS QSK60 ENGINE781
XS1425 CUMMINS QSK60 ENGINE782

IMAGES PREVIEW OF THE MANUAL:

S.M 14/12/24